Electrical component terminal

ABSTRACT

An electrical component terminal is provided utilizing a concentric extension foot and a cooperating fluted rivet whereby integral mechanical and electrical contact is achieved between the foot and the fluted rivet through the seal member in the component.

limited States Patent [1 1 Pearce et a1.

1 41 ELECTRICAL COMPONENT TERMINAL [75] lnventors: Godfrey R. Pearce;William .1. Breeden, both of Glasgow, Ky.

[73] Assignee: P. R. Mallory & Co. Inc.,

' Indianapolis, Ind.

[22] Filed: Feb. 4, 1972 [21] Appl. No.: 223,634

[52] US. Cl 317/230, 174/52 S, 339/214 C,

339/220 R, 339/220 C, 339/276 C [51] Int. Cl I-I0lg 9/10, H01r 9/14 [58]Field of Search 174/50.56, 52 S,

174/153 R; 317/230; 339/147 C, 214 R, 214 C, 218 C, 220 C, 275 A, 276 C,277 C, 278 A, 219 R, 220 R, 220 L, 220 T; 200/166 B,

1 Oct. 16, 1973 2,225,801 12/1940 Schnoll 174/52 S UX 2,465,654 3/1949Millard 339/214 R 3,439,232 4/1969 Van Buskirk et a1 174/52 S X3,548,264 12/1970 Carino et a1 174/52 S X FOREIGN PATENTS ORAPPLICATIONS 1,186,529 2/1965 Germany 339/219 R 1,028,657 2/1953 France339/214 R 1,065,157 12/1953 France 339/214 R 1,147,809 6/1957 France317/230 556,689 2/1957 Italy 174/52 S Primary Examiner-Laramie E. AskinAttorney-Richard H. Childress et a1.

[5 7] ABSTRACT An electrical component terminal is provided utilizing aconcentric extension foot and a cooperating fluted rivet wherebyintegral mechanical and electrical contact is achieved between the footand the fluted rivet through the seal member in the component.

12 Claims, 3 Drawing Figures 1 ELECTRICAL COMPONENT TERMINAL Asignificant problem has arisen in the connection of tabs from anelectrical component body (including, for example, capacitors, resistorsand semi-conductor devices) to terminals for connecting the device intoan electrical circuit. Particularly in the case of capacitors, a numberof failures have been observed in the connection between thetabs and theterminal involving a rivet member and these failures have beenparticularly recurrent where high current and/or heavy duty cycleapplications have been involved.

One proposed solution to this problem is described in Van Buskirk et al.U.S. Pat. No. 3,439,232. In this patent, a hollow bushing is utilizedthrough which the rivet connector member passes. However, failures havestill occurred and the use of the hollow bushing involves a significantoutlay.

Another technique which has been utilized to connect the tab members tothe terminals is described in US. Pat. No. 2,225,801. In this technique,the tab member is inserted into a hollow stud member. After insertion ofthe tab, the lower portion of the stud is pinched to hold the lowerportion of the stud in engagement with the tab.

The terminal member is pierced through the phenolic disc so that theteeth on the terminal member engage the disc. Thus, the disc forms anintegral part of the support structure for the electrical connectionbetween the pin portion of the stud and the hole in the terminal member.Since the searated teeth are flared outwardly, there is not as muchsurface area available for contact as desired between the pin and thehole. Thus, overheating may occur when high currents or heavy dutycycles are utilized in operation.

Thus, it is apparent that there is a need for an electrical componentterminal connection assembly which avoids the over-heating and resultingopen circuiting of terminal connections, particularly where highcurrents and/or heavy duty cycles are encountered.

It is therefore an object of the present invention to provide a terminalstructure which is easy to manufacture and assemble.

It is another object of the present invention to provide a terminalconstruction at low cost.

- Other objects will be apparent from the following description anddrawings wherein:

FIG. 1 is an exploded view in perspective of the terminal constructionof the present invention;

FIG. 2 is a sectional view illustrating the terminal construction afterassembly; and

FIG. 3 is a view of an assembled capacitor utilizing the terminalconnection assembly of the present invention.

As can be seen from FIG. 1, the assembly of the present inventioncomprises a terminal member indicated generally as having an externalconnection portion 11 and an internal connection portion 12, preferablyat 90 with respect to said external connection portion. The internalconnection portion has an opening 13, and an extension or foot 14,preferably perpendicular to the body of the internal connection portion.

The extension or foot is adapted to enter into the upper portion of aseal member 20. The seal member comprises an upper member 21 ofrelatively hard plastic or thermosetting material such as phenolic orBAKELITE and a lower member 22 made of soft rubher which may be of anyof the known soft natural or synthetic rubbers. Each of the members 21and 22 has an opening therein, respectively, 23 and 24. As can be seenfrom FIG. 2, the foot 14 enters into at least a portion of the upperseal member 21.

A very important aspect of the present invention is the rivet which isshown generally at 30 in FIG. 1. This rivet comprises a base portion 31,preferably having on the upper or contacting surface thereof, aplurality of dimples 32. The rivet also comprises a longitudinal shankportion 33 (with respect to base 31), preferably cylindrical andpreferably having thereon a plurality of flutes 34. Generally from twoto eight such flutes may conveniently be utilized. More flutes thaneight do not improve the device significantly. One flute generally doesnot provide sufficient contact around the circumference to achieve thefull benefit of the use of flutes. Longitudinal portion or shank portion33 also preferably has an opening 35 which extends down to from aboutone-third to onerhalf of the distance from the top of the shank to thebase.

The other parts of the assembly include a plurality of tabs 40 connectedto the component body. As mentioned above, the component may be acapacitor, a re sistor, a semiconductor device, inductance orcombination of the foregoing. For example, as shown in FIG. 3, tabs 40may be connected to capacitor electrodes 71, 72 of the capacitor body70. Each of the tabs has opening 41 placed in engagement with the rivetbase portion 31; and a washer 50 having an opening 51 is used to holdthe tabs in place upon base portion'31.

The method of assembly of the terminal assembly is as follows: First,the tab 40 is placed upon rivet 30 and the tab is pulled downsufficiently to engage the base portion 31 and preferably engage thedimples 32. Next, washer 50 is placed over tab 40 so that the lowersurface 52 engages the upper surface 43 of tab 40.

Next, terminal member 10 is placed upon the disc 20 with the extensionfoot 14 in place within opening 23 of the disc. Then the shank portion33 of rivet 30 with tab 40 and washer 50 in place is brought up throughthe disc 20 and opening 13 in terminal 10 so that at least a rivetingportion 36 extends through and above internal connection portion 12.

. It will be noted that the openings 23 and 24 in the disc are ofgreater diameter than the diameter of the rivet shank 33.

As shown in FIG. 2, the riveting operation results in engagement ofshank portion 36 with internal contacting portion 12 of terminal 10 at61. Engagement also is achieved by the rivet shank 33 with the internalsurface of the extension foot 14 at 62. Furthermore, the rivetingoperation-results in flutes 34 being driven outwardly and upwardly sothat a substantial amount of engagement is achieved between flutes 34and the under surface 15 of foot 14 at 63.

As mentioned previously, a very important problem with prior assembliesis achieving sufficient contact area so that in handling high currents(above about 5 amps) or heavy duty cycles (such as a current of about 5amps or higher is used for more than milliseconds for more than 5, forexample, 6 to 12, times per hour) sufficient heat being generated at thecontact area to melt a portion of one or more of the members will beavoided. In general, the terminal member 10 is made of steel and all ofthe other members of the assembly including rivet 30, tab 40, and washer50 are made of aluiron or steel could be used for other members of theassembly in addition to terminal number 10.

The present invention is particularly adapted to the connectingassemblies in A.C. motor start capacitors where currents of about 20-25amps and higher at up to 100 volts and higher are utilized and the dutycycle is heavy during the period the operator is starting the device.For example, the duty cycle may be above 100 milliseconds 8-15 times perhour or higher.

However, with the construction of the present invention wherein goodmechanical and electrical contact and engagement is obtained at 61, 62and 63, the problem of heating and melting is largely overcome interminal assemblies even where high currents and/or heavy duty cyclesare involved.

Another important advantage of the present invention is that theassembly is relatively independent of deterioration of the disc member20. All the contacting points are integrally engaged after the rivetingopera tion so that deterioration of anyportion of the disc 20 does notlessen the integral bond and electrical contact of the assembly.

An example of a completed device is shown in FIG. 3. The deviceillustrated is a capacitor, but the component body could just as well beone of the other components or combinations thereof mentioned above.Wound metal conducting electrodes 71 and 72 are separated by a separatoror spacer member 73 made of paper or plastic. Preferably an electrolyteis impregnated into the spacer in a known manner. Tabs 40 contact theelectrodes 71 and 72 and contact rivet base portion 31 and .washer 50-ofthe terminal assembly as described above. A metal or plastic case 80'isused to house the assembly. A material such as tar 81 may be provided toprotect the capacitor body against camming and vibration.

What is claimed is:

1. A terminal assembly adapted to project through an opening in sealmeans closing an open end of a housing for an electrical component, theterminal assembly comprising terminalmember means including an externalconnection portion and an internal connection portion, an opening in theinternal connection portion and extension means concentric with theopening of the internal connection portion projecting from the internalconnection portion, the extension means adapted to project into theopening of the seal means, and means projecting through the opening ofthe internal connection portion including a portion adapted to assist inretaining tab means of the electrical component, the means includingshank means having flute means, the extension means of the internalconnection portion in contact with the flute means by moving theextension means relative to the flute means to drive at least some ofthe flute means outwardly from the shank means, a flanged portion of theshank means engaging with the internal connection portion to lock themeans including the shank means to the terminal member means.

2, The terminal assembly of claim 1, wherein the flute means is aplurality of flutes integral with and elongated in the direction of thelongitudinal axis of the shank means.

3. The terminal assembly of claim 2, wherein the extension means is madefrom a metal harder than the metal of the flutes.

4. The terminal assembly 'of claim 3, wherein the extensionmeans ismetal selected from the group including iron and steel, and the flutesare a metal selected from the group including aluminum, aluminum alloys,and copper, silver, gold and their alloys.

5. The terminal assembly of claim 1, wherein the extension means isadapted to engage with the wall of the opening of the seal means.

6. The terminal assembly of claim 5, wherein the.

means including the shank means is a rivet-like means including basemeans having a contact surface with a plurality of dimples, and washermeans adjacent the contact surface of the base means, the contactsurface and washer means adapted to grip and assist in retaining the tabmeans of the electrical component.

7. The terminal assembly of claim 6, wherein the external connectionportion of the terminal member means is at an angle of about withrespect to the internal connection portion.

8. The terminal assembly of claim'l, wherein the internal connectionportion and the external connection portion are at an angle with respectto each other, the means including the shank means is a rivet-like meansincluding a base means having a contact surface with dimple meansadapted to assist in retaining the tab means, the shank means projectingfrom the base means-and having the flu-te means integral with andelongated in the direction of the longitudinal axis of. the shank means,the extension means of the internal connection portion in contact withthe flute means by moving the extension means relative to the flutemeans to.

drive the flute means toward the base means and outwardlyfrom the shankmeans to occupy more of the opening of the seal means. j

' 9.. The terminal assembly of claim 8, wherein the extension means is ahard metal and the flute means is a soft metal.

10. The terminal assembly of claim8, including a washer cooperativelyassociated with the contact surface of the base of the rivet-like meansto assist in retaining the tab means.

11. The terminal assembly of claim 10, wherein the extension means isadapted to engage with the wall of the opening of the seal means.

12. A capacitor including anode electrode means and cathode electrodemeans, dielectric means between the anode electrode means and thecathode electrode means, electrolyte means cooperatively associated withthe anode electrode means and the cathode electrode means, tab meanscontacting one of the electrode means and having a portion retained bythe terminal assembly of claim 1.

H UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PatentNo msmmizDated 10/1 /73 Inventor(s) Godfrey R. Pearce; William J. Breeden It iscertified that error appears in the above-identified patent and thatsaid Letters Patent are hereby corrected as shown below:

Column 3, line 2, change "66 to ---66O Signed and sealed this 9th day ofApril 1971+.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. c. MARSHALL DANN Attesting Officer Commissioner ofPatents FORM PO-105O (10-69) USCOMM-DC 60376-P69 fi u.s. GOVERNMENTPRINTING OFFICE: 1969 0-366-334 UNITED STATES PATENT OFFICE TI ATE OFCORRECTION Patent No 3 Z66 ,L;) 2 v Dated /73 Inventor(s) Godfrey R.Pearce; William J. Breeden It is certified that error appears in theabove-identified patent and that said Letters Patent are herebycorrected as shown below:

Colwnn 3, line 2, change "66" to ---660---- Signed and sealed this 9thday of April 197b,.

(SEAL) Attest: I

EDWARD M.FLETCHER,JR. or. MARSHALL, DANN Attesting Officer 7Commissioner of Patents FORM PO-1050 (10-69) u c 60376.p69

- u.s. sovsnnmsm PRINTING omcz I969 o-ass-au

1. A terminal assembly adapted to project through an opening in seal means closing an open end of a housing for an electrical component, the terminal assembly comprising terminal member means including an external connection portion and an internal connection portion, an opening in the internal connection portion and extension means concentric with the opening of the internal connection portion projecting from the internal connection portion, the extension means adapted to project into the opening of the seal means, and means projecting through the opening of the internal connection portion including a portion adapted to assist in retaining tab means of the electrical component, the means including shank means having flute means, the extension means of the internal connection portion in contact with the flute means by moving the extension means relative to the flute means to drive at least some of the flute means outwardly from the shank means, a flanged portion of the shank means engaging with the internal connection portion to lock the means including the shank means to the terminal member means.
 2. The terminal assembly of claim 1, wherein the flute means is a plurality of flutes integral with and elongated in the direction of the longitudinal axis of the shank means.
 3. The terminal assembly of claim 2, wherein the extension means is made from a metal harder than the metal of the flutes.
 4. The terminal assembly of claim 3, wherein the extension means is metal selected from the group including iron and steel, and the flutes are a metal selected from the group including aluminum, aluminum alloys, and copper, silver, gold and their alloys.
 5. The terminal assembly of claim 1, wherein the extension means is aDapted to engage with the wall of the opening of the seal means.
 6. The terminal assembly of claim 5, wherein the means including the shank means is a rivet-like means including base means having a contact surface with a plurality of dimples, and washer means adjacent the contact surface of the base means, the contact surface and washer means adapted to grip and assist in retaining the tab means of the electrical component.
 7. The terminal assembly of claim 6, wherein the external connection portion of the terminal member means is at an angle of about 90* with respect to the internal connection portion.
 8. The terminal assembly of claim 1, wherein the internal connection portion and the external connection portion are at an angle with respect to each other, the means including the shank means is a rivet-like means including a base means having a contact surface with dimple means adapted to assist in retaining the tab means, the shank means projecting from the base means and having the flute means integral with and elongated in the direction of the longitudinal axis of the shank means, the extension means of the internal connection portion in contact with the flute means by moving the extension means relative to the flute means to drive the flute means toward the base means and outwardly from the shank means to occupy more of the opening of the seal means.
 9. The terminal assembly of claim 8, wherein the extension means is a hard metal and the flute means is a soft metal.
 10. The terminal assembly of claim 8, including a washer cooperatively associated with the contact surface of the base of the rivet-like means to assist in retaining the tab means.
 11. The terminal assembly of claim 10, wherein the extension means is adapted to engage with the wall of the opening of the seal means.
 12. A capacitor including anode electrode means and cathode electrode means, dielectric means between the anode electrode means and the cathode electrode means, electrolyte means cooperatively associated with the anode electrode means and the cathode electrode means, tab means contacting one of the electrode means and having a portion retained by the terminal assembly of claim
 1. 